Modular fan systems and assemblies

ABSTRACT

A modular fan assembly includes a fan unit and a mount assembly removably connected to the fan unit. The fan unit may include a fan housing, an impeller disposed within the fan housing, a motor coupled to the impeller to drive the impeller, and first electrical contacts disposed on the fan housing. The first electrical contacts can electrically communicate with the motor. The mount assembly may include a support housing removably connected to at least a portion of the fan housing and second electrical contacts disposed on the support housing. The second electrical contacts can electrically communicate with the first electrical contacts.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Patent Application No. 62/636,186, filed Feb. 28, 2018, the entire contents of which are hereby incorporated by reference herein.

BACKGROUND

The present disclosure relates to fans and, in particular, to modular fans.

Fans are typically positioned within rooms to circulate air within that room. Some fans include blades or impellers positioned within a housing such that the blades or impellers are not visible to a user. These fans are commonly referred to as bladeless fans. A bladeless fan typically draws air through an opening in the housing and guides the air through inner pathways until the air is pushed out of airways in a desired direction. Taking advantage of the Bernoulli principle and Coanda effect, the geometry uses high velocity air expelled from the airways to draw additional surrounding air into the airflow zone, increasing a total air flow.

SUMMARY

In one embodiment, a modular fan assembly may include a fan unit and a mount assembly removably connected to the fan unit. The fan unit may include a fan housing, an impeller disposed within the fan housing, a motor coupled to the impeller to drive the impeller, and first electrical contacts disposed on the fan housing. The first electrical contacts can electrically communicate with the motor. The mount assembly may include a support housing removably connected to at least a portion of the fan housing and second electrical contacts disposed on the support housing. The second electrical contacts can electrically communicate with the first electrical contacts.

In another embodiment, a method of assembling a modular fan assembly may include providing a fan unit. The fan unit may include a fan housing, an impeller disposed within the fan housing, a motor coupled to the impeller to drive the impeller, and fan electrical contacts disposed on the fan housing. The method may also include providing a first mount assembly. The first mount assembly may include a first support housing removably connectable to at least a portion of the fan housing and first mount electrical contacts positioned to electrically couple to the fan electrical contacts. The method may further include providing a second mount assembly. The second mount assembly may include a second support housing removably connectable to at least a portion of the fan housing and second mount electrical contacts positioned to electrically couple to the fan electrical contacts. The method may also include selectively coupling the fan unit to the first mount assembly or the second mount assembly.

In another embodiment, a modular fan system may include a fan unit, a first mount assembly removably connectable to the fan unit, and a second mount assembly removably connectable to the fan unit. The fan unit may include a fan housing, an impeller disposed within the fan housing, a motor coupled to the impeller to drive the impeller, and fan electrical contacts electrically coupled to the motor. The first mount assembly may include a first support housing. The first support housing may removably receive at least a portion of the fan housing. The first support housing may be adjustable relative to at least a portion of the first mount assembly. First mount electrical contacts may be positioned to electrically couple to the fan electrical contacts upon connecting the first mount assembly to the fan unit. The second mount assembly may include a second support housing. The second support housing may removably receive at least a portion of the fan housing. The second support housing may be adjustable relative to at least a portion of the second mount assembly. Second mount electrical contacts may be positioned to electrically couple to the fan electrical contacts upon connecting the second mount assembly to the fan unit.

Other aspects of the disclosure will become apparent by consideration of the detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a modular fan assembly.

FIG. 2 is an exploded view of the modular fan assembly of FIG. 1.

FIG. 3 is a perspective view of a modular fan assembly according to another embodiment of the disclosure.

FIG. 4 is an exploded view of the modular fan assembly of FIG. 3.

FIG. 5 is a perspective view of a modular fan assembly according to another embodiment of the disclosure.

DETAILED DESCRIPTION

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of other embodiments and of being practiced or of being carried out in various ways.

FIGS. 1-5 illustrate different embodiments of a modular fan assembly, generally designated 100, 200, 300. The modular fans 100, 200, 300 may be intended for use within a room to create airflows within that room.

With reference to FIGS. 1-2, the modular fan assembly 100 may include a fan unit 110 that may be removably connected to a mount assembly 114 (e.g., a base). In this way, a single fan unit 110 may be connected (e.g. physically connected, mechanically connected, electrically connected, and/or the like) to any one of a plurality of different types of mount assemblies (e.g., floor mount assemblies, pedestal mount assemblies, wall mount assemblies, ceiling mount assemblies, and/or the like) for providing a modular, customizable fan. Further, in this way, any one of a plurality of different types of fan assemblies (e.g., bladed fan assemblies, bladeless fan assemblies, and/or the like) may be connected a single mount assembly 114. In this way, a user may assemble a fan suitable for use in a desired space and/or suitable for use in a desired application (e.g., for ventilation, for floor drying, and/or the like).

The fan unit 110 may include a motor 116, a fan housing 118, and an impeller 120. The impeller 120 may be disposed within the fan housing 118 and be coupled to an output shaft of the motor 116. The output shaft may extend along (e.g., parallel to) an impeller rotation axis A1 of the fan unit 110. The motor 116 may also be disposed within the fan housing 118. The motor 116 may drive (e.g., rotate) the impeller 120 by way of the output shaft causing the impeller 120 to rotate about the rotation axis A1 and induce an airflow. In some embodiments, the nozzle 126, the motor 116, and/or the impeller 120 may be co-axial respective to the impeller rotation axis A1 and/or concentric.

The fan housing 118 may include an air inlet 122 and a nozzle 126 in fluid communication with the air inlet 122. The nozzle 126, as shown in the illustrated embodiment, may be an annular nozzle. Other embodiments may include a nozzle 126 that may be square, rectangular, oblong, elliptical, oval, hexagonal, octagonal, and/or the like. In some embodiments, the nozzle 126 may be positioned about the motor 116 and the impeller 120. Air may be drawn into the annular nozzle 126 by way of rotating the impeller 120, drawing the air in through the air inlet 122, and forcing the air into the nozzle 126 from which the air may ultimately be expelled. In the illustrated embodiment, the air inlet 122 may be comprised of a series of air vents 130 (see e.g., FIG. 2) that are formed in the fan housing 118 and/or a support housing 158 that supports the fan housing 118, as described in more detail below. In other embodiments, the air inlet 122 may be an opening or a slot that allows air to pass into the fan housing 118 of the fan unit 110.

The fan unit 110 may additionally include electrical contacts 134 (see e.g., FIG. 2) disposed on, over, and/or in portions of the fan housing 118. The electrical contacts 134 may extend about a periphery of the fan housing 118. The electrical contacts 134 may be positioned on a side opposite of the nozzle 126, for example, and be disposed proximate to the mount assembly 114. In the illustrated embodiment, the fan unit 110 may include four electrical contacts 134. In other embodiments, the fan unit 110 may include fewer or more electrical contacts 134. In further embodiments, the electrical contacts 134 may be formed as an electrical plug, socket, or other type of connector (e.g., an adapter, a port (e.g., an HDMI port, a USB port, and/or the like), a dongle, and/or the like). The electrical contacts 134 may be configured to route electrical current or power from the mount assembly 114 to portions of the motor 116 for energizing the motor 116 and rotating the impeller 120 to generate an airflow as described herein. In this way, the fan unit 110 may be electrically compatible with and/or interchangeable respective to a plurality of different types of fan mounts (e.g., fan assemblies 114) as described herein.

With continued reference to FIGS. 1-2, the nozzle 126 may be positioned around the fan housing 118. The fan unit 110, thereby, may define a central opening 138 between the nozzle 126 and the fan housing 118. The central opening 138 may include an open space formed between portions of the nozzle 126 and the fan housing 118. The nozzle 126 may also include at least one outlet 142 defined therein. The outlet 142 may include one or more openings. The outlet 142 may be one or more slits, slots, holes, openings, and/or the like. The outlet 142 may extend at least partially about the fan housing 118 along the nozzle 126. In embodiments including an annular nozzle 126, the outlet 142 may include an annular outlet that extends at least partially around an inner perimeter of the annular nozzle 126. In some embodiments, the annular outlet 142 may extend completely around the inner perimeter of the annular nozzle 126. One or more arms 146 may connect (e.g., physically connect, fluidly connect, and/or the like) the fan housing 118 to the annular nozzle 126 and, thus, support the fan housing 118 respective to the nozzle 126. In the illustrated embodiment, the fan unit 110 may include two arms 146. In other embodiments, the fan unit 110 may include one arm 146 or more than two arms 146. Each arm 146 may include an air passageway 148 disposed therein that allows the fan housing 118 to be in fluid communication with the annular nozzle 126. In some embodiments, the fan unit 110 may include a light (e.g., a bulb, a LED, and/or the like) positioned on, over, and/or in the fan housing 118. The central opening 138 may be defined between the nozzle 126 and the fan housing 118, and may be divided by the one or more arms 146.

In the illustrated embodiment, the mount assembly 114 may include a base member 150, an elongated support member 154, and a support housing 158. The base member 150 may be a wall or ceiling mount, and the elongated support member 154 may be a wall or ceiling mount arm. The base member 150 may be configured to be mounted to a wall or a ceiling of a room via fasteners 162 (e.g., screws, nails, bolts, etc.). The elongated support member 154 may be connected to the base member 150 and may include a bifurcated end 166 that movably supports the support housing 158. In some embodiments, the elongated support member 154 may be a swivel arm that allows the fan unit 110 to be positioned in various positions. The support housing 158 may be pivotally connected to the bifurcated end 166 of the elongated support member 154 to allow the support housing 158 to rotate relative to the elongated support member 154 about a pivot axis A2. The pivot axis A2 may be perpendicular to the impeller rotation axis A1.

With reference to FIG. 2, the support housing 158 may include or define a cavity 170, in which electrical wiring 174 may be positioned, and the support housing 158 may include or define a plurality of air vents 130 disposed on an outer periphery thereof. The electrical wiring 174 may be connected to a power source (e.g., a wall outlet, a power strip, a generator, and/or the like) within the room that the fan unit 110 may be located. In some embodiments, the electrical wiring 174 may extend out the back (rear) of the support housing 158 to a power source (see e.g., FIG. 1). In other embodiments, the electrical wiring 174 may extend from the back of the support housing 158 and internally through the elongated support member 154 (see e.g., FIG. 2). The support housing 158 may further include electrical contacts 178 that correspond to the electrical contacts 134 on the fan housing 118 of the fan unit 110. For example, the electrical contacts 178 of the support housing 158 may correspond in size, shape, location, quantity, material, and/or the like, to the electrical contacts 134 of the fan housing 118. In some embodiments, the electrical contacts 178 of the support housing 158 may be configured to contact and align with the electrical contacts 134 of the fan housing 118 upon positioning the fan housing 118 respective to the support housing 158. In this way, the electrical contacts 178 of the support housing 158 may electrically couple and/or communicate with the electrical contacts 134 of the fan housing 118 so that power from the power source may be routed towards the fan unit 110. In the illustrated embodiment, the electrical contacts 178 and 134 may be electrically conductive contacts, such as metal or metal-alloy contacts (e.g., comprising copper, silver, gold, tin, aluminum, iron, and/or the like). Steel contacts may be more robust, in some embodiments, and resist frictional wear during the repeated insertion and removal of the fan unit 110 respective to the mount assembly 114. In other embodiments, the electrical contacts 178 may include other types of electrically conductive materials (e.g., conductive paints, conductive polymers, and/or the like).

As shown in FIG. 2, the fan unit 110 may be removably connected to the mount assembly 114. In some embodiments, the fan unit 110 may be inserted in the cavity 170 of the mount assembly 114 in an insertion direction D1. The insertion direction D1 may be parallel to or collinear with the rotation axis A1 of the impeller 120. To connect the fan unit 110 to the mount assembly 114, the fan housing 118 of the fan unit 110 may be positioned within the cavity 170 of the support housing 158 of the mount assembly 114. The fan unit 110 may then be rotated until the electrical contacts 134 of the fan unit 110 align, contact, and/or otherwise electrically connect or couple with the electrical contacts 178 of the mount assembly 114, allowing electricity to flow therebetween to power the fan unit 110. In some embodiments, the mount assembly 114 or the fan unit 110 may include a coupling mechanism (e.g., a latch, a quick-release connect mechanism, a tongue-in-groove coupler, and/or the like) and/or a locking mechanism to further couple and/or lock the fan unit 110 to the mount assembly 114. The fan unit 110 may be removed from the mount assembly 114 and positioned in another mount assembly that is located elsewhere. In some embodiments, the fan unit 110 may mount to the mount assembly 114 without the use of a tool (e.g., without the use of a power tool, a hand tool, and/or the like). For instance, the fan unit 110 may be frictionally held in place, may snap into place, may slide into place, may rotate into place, may be accommodated in one or more angled slots, and/or the like.

During operation of the modular fan assembly 100, electrical current or power may be provided by a power source and be routed to the motor 116 by way of routing the power through the electrical wiring 174 and the electrical contacts 134, 178. The motor 116 may rotate the impeller 120 to draw air from outside the fan unit 110 through the air vents 130 of the air support housing 158 and the air inlet 122 and into the fan housing 118. The impeller 120 may continue to push the air through the arms 146 and into the annular nozzle 126. Air pressure may begin to build within the annular nozzle 126 as more air is pushed into the annular nozzle 126. Once the air pressure is high enough, the air may be continually expelled from the annular outlet 142 and away from the fan unit 110. Due to the high air pressure, the air may be expelled at a high velocity, drawing air surrounding the fan unit 110 through the central opening 138 and creating an amplified airflow effect.

FIGS. 3-4 illustrate a modular fan assembly 200 according to another embodiment of the disclosure. The modular fan assembly 200 may be similar to the modular fan assembly 100 of FIG. 1, with like features being represented by like reference numerals. The modular fan assembly 200 may include the fan unit 110, but instead of a mount assembly 114 with a base member 150 being formed as a wall mount, may include a mount assembly 210 with being formed as a floor mount 214. The floor mount 214 may include a base member 218, an elongated support member 222 with a bifurcated end 226, and a support housing 230. The base member 218 may be a support base, and the elongated support member 222 may be an elongated stem. Similar to the modular fan assembly 100, the fan unit 110 may be positioned within the support housing 230 with the electrical contacts 134 on the fan housing 118 of the fan unit 110 facing and connected to the electrical contacts 178 on the support housing 230 of the floor mount 214. In the illustrated embodiment, the electrical wiring 174 may extend through the elongated stem 222 of the floor mount 214 and out of the support base 218 to be connected to a power source. In some embodiments, the elongated stem 222 may have a length of, for example, about two feet, about three feet, about four feet, about five feet, about ten feet, or more than ten feet. Additionally, or alternatively, the length of the elongated stem 222 may be adjustable by, for example, by way of a telescoping mechanism.

FIG. 5 illustrates a modular fan assembly 300 according to another embodiment of the disclosure. The modular fan assembly 300 may be similar to the modular fan assembly 200 of FIG. 2, with like features being represented with like reference numerals. The modular fan assembly 300 may include the fan unit 110, but may include a mount assembly 310 with a floor mount 314 that has an elongated support member (or elongated stem) 318 that is shorter than the elongated stem 222 shown in FIGS. 3-4. The shorter elongated stem 318 may be more conducive for positioning the modular fan assembly 300 on a desk, table, or stand. In some embodiments, the elongated stem 318 may have a length that is less than two feet. For example, the length of the elongated stem be six inches, one foot, 1.5 feet, and/or the like.

As discussed above, the fan unit 110 may be removably connected to a mount assembly 114, 210, 310. The fan unit 110 may be removed from one mount assembly 114, 210, 310 and connected to another mount assembly 114, 210, 310 with or without the use of one or more tools. For example, the fan unit 110 may be removed from the mount assembly 114 with the base member 150 and positioned into the mount assembly 210 with the elongated stem 222 or the mount assembly 310 with the shorter stem 318. The fan unit 110 may be pivotable and/or rotatable respective to the respective mount assembly by way of pivoting and/or moving about a pivot axis (e.g., A2) and/or moving about a universal joint.

A fan unit 110 that is removably connected to a mount assembly 114, 210, 310 allows for the easy repositioning of the fan unit 110 within a room. The convenience of a removable fan unit 110 allows for the fan unit 110 to provide airflow in a variety of ways within a room, and/or allows the fan unit 110 to be moved from room to room.

Various features and advantages of the disclosure are set forth in the following claims. 

What is claimed is:
 1. A modular fan assembly comprising: a fan unit including: a fan housing; an impeller disposed within the fan housing; a motor coupled to the impeller to drive the impeller; and first electrical contacts disposed on the fan housing, wherein the first electrical contacts are configured to electrically communicate with the motor; a mount assembly removably connected to the fan unit, the mount assembly including: a support housing removably connected to at least a portion of the fan housing; and second electrical contacts disposed on the support housing, wherein the second electrical contacts are configured to electrically communicate with the first electrical contacts.
 2. The modular fan assembly of claim 1, wherein the fan unit is adjustable relative to a portion of the mount assembly when the fan unit is connected to the support housing.
 3. The modular fan assembly of claim 1, wherein the mount assembly further includes an elongated support member connected to the support housing.
 4. The modular fan assembly of claim 3, wherein the support housing is movable respective to the elongated support member.
 5. The modular fan assembly of claim 3, wherein the mount assembly further includes a base member connected to the elongated support member.
 6. The modular fan assembly of claim 5, wherein the base member is configured to mount to a wall.
 7. The modular fan assembly of claim 5, wherein the base member is configured to mount to a ceiling.
 8. The modular fan assembly of claim 5, wherein the base member is configured to contact a floor.
 9. The modular fan assembly of claim 1, wherein the fan unit further includes a nozzle configured to direct air leaving the fan unit.
 10. The modular air assembly of claim 9, wherein the fan unit further includes at least one arm connecting the nozzle to the fan housing.
 11. The modular air assembly of claim 9, wherein the fan unit further includes at least one central opening defined between the nozzle and the fan housing.
 12. The modular fan assembly of claim 1, wherein the fan unit further includes at least one air intake vent defined in the fan housing.
 13. The modular fan assembly of claim 12, wherein the mount assembly further includes at least one air intake port defined in the support housing, the at least one air intake port being fluidly coupled to the at least one air intake vent.
 14. The modular fan assembly of claim 1, wherein: the support housing defines a cavity, and at least a portion of the fan housing is removably received in the cavity.
 15. The modular fan assembly of claim 1, wherein the support housing removably receives the fan housing in a linear insertion direction.
 16. The modular fan assembly of claim 15, wherein the linear insertion direction is parallel to a rotation axis of the impeller.
 17. A method of assembling a modular fan assembly, the method comprising: providing a fan unit including: a fan housing; an impeller disposed within the fan housing; a motor coupled to the impeller to drive the impeller; and fan electrical contacts being disposed on the fan housing; providing a first mount assembly including: a first support housing being removably connectable to at least a portion of the fan housing; and first mount electrical contacts positioned to electrically couple to the fan electrical contacts; providing a second mount assembly including: a second support housing being removably connectable to at least a portion of the fan housing; and second mount electrical contacts positioned to electrically couple to the fan electrical contacts; and selectively coupling the fan unit to the first mount assembly or the second mount assembly.
 18. The method of claim 17, wherein selectively coupling the fan unit to the first mount assembly or the second mount assembly includes: physically coupling the fan housing to the first support housing or the second mount assembly, and electrically coupling the fan electrical contacts to the first mount electrical contacts or the second mount electrical contacts.
 19. The method of claim 17, wherein selectively coupling the fan unit to the first mount assembly or the second mount assembly is accomplished without the use of a tool.
 20. A modular fan system comprising: a fan unit including: a fan housing; an impeller disposed within the fan housing; a motor coupled to the impeller to drive the impeller; and fan electrical contacts electrically coupled to the motor; a first mount assembly removably connectable to the fan unit, the first mount assembly including: a first support housing to removably receive at least a portion of the fan housing, the first support housing adjustable relative to at least a portion of the first mount assembly; and first mount electrical contacts positioned to electrically couple to the fan electrical contacts upon connecting the first mount assembly to the fan unit; and a second mount assembly removably connectable to the fan unit, the second mount assembly including: a second support housing to removably receive at least a portion of the fan housing, the second support housing adjustable relative to at least a portion of the second mount assembly; and second mount electrical contacts positioned to electrically couple to the fan electrical contacts upon connecting the second mount assembly to the fan unit. 